As the world’s largest injection moulding machine, the ENGEL duo 12000 US enables the cost-efficient production of large-format injection-moulded parts in previously unattained dimensions for new product concepts with reduced assembly effort and an improved CO2 footprint

The large mould space enables flexible automation and the efficient production of complex, large-scale components in integrated production processes

ENGEL builds the world’s largest injection moulding machine with the duo 12000 US

WITH the duo 12000 US, ENGEL expands industrial production of large-format injection-moulded parts to previously unattained dimensions. The two-platen injection moulding machine enables the reduction of part costs for large-area components.

The 110,000kN clamping force was specifically developed for parts with projected areas of more than 2.5m². Commissioned at the customer’s site, this machine enables cost-efficient production of very large-format components in an integrated production process. With injection moulding solutions of this scale, manufacturers can produce large-format structures in a single production step. This reduces material usage, simplifies production logistics, and saves time and costs.

The system is equipped with two injection units operating in parallel, allowing for large shot weights for large-area components. The screw diameters of up to 210mm enable a shot volume of up to 65,000cm³ and homogeneous filling of large projected areas.

The dimensions of the system illustrate the technical challenge: with a length of around 24m and a height of approximately 8.4m, it is among the largest industrial production systems in injection moulding worldwide. The total weight is 551 tonnes, with a maximum mould weight of 170 tonnes. Despite these dimensions, the machine remains compact with its modular, duo design to save floor space.

High vertical integration and comprehensive process expertise
Injection moulding solutions of this scale are developed exclusively for specific customer requirements. The in-house large machine technical centre enables customers to carry out extensive tests for technology and part development. Especially for large volume components, shrinkage behaviour plays a decisive role. In this technical centre, ENGEL can carry out iterations and optimisations to ensure the required part quality.

Many years of experience in the construction of large machines
ENGEL has decades of experience in the development and realisation of large machines. Despite their dimensions, large machines are characterised by exceptional precision. Through options such as injection compression moulding, the component dimensions can be defined with an accuracy of a few hundredths of a millimetre, a level of precision comparable to the thickness of a sheet of paper. This sensitivity, combined with enormous force, opens new possibilities in precision lightweight construction and in the functional integration of large-format components.

Gigamoulding enables new vehicle architecture
In the automotive sector, demand for gigamoulding solutions for large structural components is increasing. Megatrends such as electromobility, autonomous driving, platform consolidation and CO2 reduction targets are driving this development. Applications such as battery housings, underbody panels or hybrid inner door structures can be rethought through the new production possibilities.

New possibilities in technical injection moulding
Large machines also increase application potential in technical injection moulding. ENGEL has successfully established machines with clamping forces of around 11,000 tonnes, among others, for logistics and infrastructure products. These include transport containers for the disposal of e-mobility batteries, large-volume infiltration boxes for rainwater management, as well as water tanks with mould areas of nearly six square metres and shot weights of up to 109kg.

Technology driver for sustainable large-scale structures
With the duo 12000 US, ENGEL reinforces its position as a technology leader in injection moulding. The system is not only a record-holder in terms of size, but also serves as a platform for new technologies, material substitution and highly integrated component concepts. It enables more sustainable product solutions in mobility, infrastructure and industry, and demonstrates the potential of gigamoulding for the industrial production of large-format structures.

ENGEL is represented in South Africa by GreenTech Plastics Machinery (Pty) Ltd.